Methods and systems for controlling temperature in a vessel

ABSTRACT

A syngas cooler system includes a pressure vessel, a conduit, a plenum, a plenum, a conduit, and a bellows assembly. The pressure vessel includes a throat and a dome adjacent to the throat. The throat includes an area of excess heat, and the dome includes an area of deficient heat. The plenum extends between the throat and the bellows assembly. The bellows assembly is coupled at least partially within the dome. The conduit is coupled to the plenum for channeling a flow of purge fluid from external to the pressure vessel into the plenum such that purge fluid transfers heat from the area of excess heat into the area of deficient heat to facilitate reducing temperature differential stresses within the dome and the pressure vessel.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a Continuation Application of, and claims priorityto U.S. patent application Ser. No. 14/279,918, filed May 16, 2014, for‘METHODS AND SYSTEMS FOR CONTROLLING TEMPERATURE IN A VESSEL,’” which isa Divisional Application of U.S. patent application Ser. No. 11/970,943,filed Jan. 8, 2008, issued as U.S. Pat. No. 8,752,615 on Jun. 17, 2014,both of which are hereby incorporated by reference and are assigned tothe assignee of the present invention.

BACKGROUND

This invention relates generally to process systems, and morespecifically to methods and systems for improving operation of pressurevessels used in gasification systems.

At least some known vessels include an annular space located near avertically upper hemispherical head of the vessel. The annular space maybe used to consolidate piping ends into headers that channel the flow offluid in the pipes to and from external to the vessel. Such piping mayresult in complex pipe routing that reduces a capability to effectivelymaintain the vessel. Specifically, a refractory lined throat thatcarries hot fluid into the vessel from, for example, a gasifier may bedifficult to maintain because of the piping located in the head.

Additionally, the hot fluid may leak into the annular space from insidethe throat. The leaking fluid may include corrosive gases that over timemay shorten the life of components in the head.

Furthermore, various materials and various thicknesses of the materialsmay be used in the fabrication of the vessel, head, and/or componentswithin the vessel and head. Because such materials and materials mayexpand and contract at different rates when exposed to changingtemperatures within the vessel. Thermal stresses may be generated thatexceed the strength and/or the cycle fatigue rating of the vessel, head,and/or components.

SUMMARY

In one embodiment, a syngas cooler system comprises a pressure vessel, aconduit, a plenum, a plenum, a conduit, and a bellows assembly. Thepressure vessel includes a throat and a dome adjacent to the throat. Thethroat includes an area of excess heat, and the dome includes an area ofdeficient heat. The plenum extends between the throat and the bellowsassembly. The bellows assembly is coupled at least partially within thedome. The conduit is coupled to the plenum for channeling a flow ofpurge fluid from external to the pressure vessel into the plenum suchthat purge fluid transfers heat from the area of excess heat into thearea of deficient heat to facilitate reducing temperature differentialstresses within the dome and the pressure vessel.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic diagram of an exemplary integrated gasificationcombined-cycle (IGCC) power generation system in accordance with anembodiment of the present invention;

FIG. 2 shows a schematic cross-sectional view of the syngas cooler shownin FIG. 1;

FIG. 3 is an elevation view of a portion of the syngas cooler inaccordance with still yet another embodiment of the present invention;

FIG. 4 is an elevation view of a portion of the syngas cooler inaccordance with a further embodiment of the present invention;

FIG. 5 is a schematic diagram of an exemplary dome purge preheatingsystem that may be used with the gasifier shown in FIG. 1;

FIG. 6 is a schematic diagram of another exemplary dome purge preheatingsystem that may be used with the gasifier shown in FIG. 1; and

FIG. 7 is a schematic diagram of yet another exemplary dome purgepreheating system that may be used with the gasifier shown in FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

The following detailed description illustrates the disclosure by way ofexample and not by way of limitation. The description clearly enablesone skilled in the art to make and use the disclosure, describes severalembodiments, adaptations, variations, alternatives, and uses of thedisclosure, including what is presently believed to be the best mode ofcarrying out the disclosure. The disclosure is described as applied to apreferred embodiment, namely, systems and methods for preheating andpurging a pressure vessel space. However, it is contemplated that thisdisclosure has general application to controlling temperature incommercial and industrial spaces.

FIG. 1 is a schematic diagram of an exemplary integrated gasificationcombined-cycle (IGCC) power generation system 10 in accordance with anembodiment of the present invention. In the exemplary embodiment, IGCCsystem 10 includes a main air compressor 12, an air separation unit(ASU) 14 coupled in flow communication to compressor 12, a gasifier 16coupled in flow communication to ASU 14, a syngas cooler 18 coupled inflow communication to gasifier 16, a gas turbine engine 20 coupled inflow communication to syngas cooler 18, and a steam turbine 22 coupledin flow communication to syngas cooler 18.

In operation, compressor 12 compresses ambient air that is thenchanneled to ASU 14. In the exemplary embodiment, in addition tocompressed air from compressor 12, compressed air from a gas turbineengine compressor 24 is supplied to ASU 14. Alternatively, compressedair from gas turbine engine compressor 24 is supplied to ASU 14, ratherthan compressed air from compressor 12 being supplied to ASU 14. In theexemplary embodiment, ASU 14 uses the compressed air to generate oxygenfor use by gasifier 16. More specifically, ASU 14 separates thecompressed air into separate flows of oxygen (O2) and a gas by-product,sometimes referred to as a “process gas.” The O₂ flow is channeled togasifier 16 for use in generating partially oxidized gases, referred toherein as “syngas” for use by gas turbine engine 20 as fuel, asdescribed below in more detail.

The process gas generated by ASU 14 includes nitrogen and will bereferred to herein as “nitrogen process gas” (NPG). The NPG may alsoinclude other gases such as, but not limited to, oxygen and/or argon.For example, in the exemplary embodiment, the NPG includes between about95% and about 100% nitrogen. In the exemplary embodiment, at least someof the NPG flow is vented to the atmosphere from ASU 14, and at some ofthe NPG flow is injected into a combustion zone (not shown) within a gasturbine engine combustor 26 to facilitate controlling emissions ofengine 20, and more specifically to facilitate reducing the combustiontemperature and reducing nitrous oxide emissions from engine 20. In theexemplary embodiment, IGCC system 10 includes a compressor 28 forcompressing the nitrogen process gas flow before being injected into thecombustion zone of gas turbine engine combustor 26.

In the exemplary embodiment, gasifier 16 converts a mixture of fuelsupplied from a fuel supply 30, O₂ supplied by ASU 14, steam, and/orlimestone into an output of syngas for use by gas turbine engine 20 asfuel. Although gasifier 16 may use any fuel, gasifier 16, in theexemplary embodiment, uses coal, petroleum coke, residual oil, oilemulsions, tar sands, and/or other similar fuels. Furthermore, in theexemplary embodiment, the syngas generated by gasifier 16 includescarbon dioxide.

In the exemplary embodiment, syngas generated by gasifier 16 ischanneled to syngas cooler 18 to facilitate cooling the syngas, asdescribed in more detail below. The cooled syngas is channeled fromcooler 18 to a clean-up device 32 for cleaning the syngas before it ischanneled to gas turbine engine combustor 26 for combustion thereof.Carbon dioxide (CO2) may be separated from the syngas during clean-upand, in the exemplary embodiment, may be vented to the atmosphere. Gasturbine engine 20 drives a generator 34 that supplies electrical powerto a power grid (not shown). Exhaust gases from gas turbine engine 20are channeled to a heat recovery steam generator 36 that generates steamfor driving steam turbine 22. Power generated by steam turbine 22 drivesan electrical generator 38 that provides electrical power to the powergrid. In the exemplary embodiment, steam from heat recovery steamgenerator 36 is supplied to gasifier 16 for generating syngas.

Furthermore, in the exemplary embodiment, system 10 includes a pump 40that supplies boiled water from steam generator 36 to syngas cooler 18to facilitate cooling the syngas channeled from gasifier 16. The boiledwater is channeled through syngas cooler 18 wherein the water isconverted to steam. The steam from cooler 18 is then returned to steamgenerator 36 for use within gasifier 16, syngas cooler 18, and/or steamturbine 22.

FIG. 2 shows a schematic cross-sectional view of syngas cooler 18 (shownin FIG. 1). In the exemplary embodiment, syngas cooler 18 is a radiantsyngas cooler. Syngas cooler 18 includes a pressure vessel shell 202having a top opening 204 and a bottom opening (not shown) that aregenerally concentrically aligned with each other along a centerline 206of syngas cooler 18. As referred to herein, an “axial” direction is adirection that is substantially parallel to centerline 206, an “upward”direction is a direction that is generally towards top opening 204, anda “downward” direction is a direction that is generally towards thebottom opening. Syngas cooler 18 includes a radius R measured fromcenterline 206 to an outer surface 208 of shell 202. Furthermore, in theexemplary embodiment, a dome 210 of cooler 18 includes dome floor 211that includes a plurality of downcomer openings 213 and a plurality ofriser openings (not shown) that circumscribe the top opening. In theexemplary embodiment, shell 202 is fabricated from a pressure vesselquality steel, such as, but not limited to, a chromium molybdenum steel.As such, shell 202 is facilitated to withstand the operating pressuresof syngas flowing through syngas cooler 18. Moreover, in the exemplaryembodiment, the shell top opening is coupled in flow communication withgasifier 16 for receiving syngas discharged from gasifier 16. The bottomopening of shell 202, in the exemplary embodiment, is coupled in flowcommunication with a slag collection unit (not shown) to enable thecollection of solid particles formed during gasification and/or cooling.

Within shell 202, in the exemplary embodiment, are a plurality of heattransfer medium supply lines (also referred to herein as “downcomers”)212, a heat transfer wall (also referred to herein as a “tube wall”)214, and a plurality of heat transfer panels (also referred to herein as“platens”) 216. More specifically, in the exemplary embodiment,downcomers 212 are positioned radially inward of shell 202, tube wall214 is radially inward of downcomers 212, and platens 216 are arrangedwithin tube wall 214 such that tube wall 214 substantially circumscribesplatens 216.

In the exemplary embodiment, downcomers 212 supply a heat transfermedium 218, such as, for example, water from steam generator 36, tosyngas cooler 18, as described herein. Downcomers 212 supply heattransfer medium 218 to tube wall 214 and platens 216 via a lowermanifold 220. Lower manifold 220, in the exemplary embodiment, iscoupled proximate to the cooler bottom opening, and, as such, isdownstream from cooler top opening 204 through which syngas enterscooler 18. In the exemplary embodiment, downcomers 212 include tubes 222fabricated from a material that enables cooler 18 and/or system 10 tofunction as described herein. Furthermore, in the exemplary embodiment,a gap 224 defined between shell 202 and tube wall 214 may be pressurizedto facilitate decreasing stresses induced to tube wall 214.

Shell 202 includes a flange 226 that may be used to couple cooler 18 togasifier 16 (shown in FIG. 1) a throat 228 extends vertically upwardfrom shell 202 to flange 226. A refractory lining 230 extends throat 228from shell 202 to dome floor 211. Syngas received from gasifier 16passes through throat 228 and refractory lining 230. Accordingly, throat228 and refractory lining 230 are subject to the high temperature of thesyngas flow. In an alternative embodiment, refractory lining 230 extendsvertically upward and radially inwardly from throat 228. In theexemplary embodiment, refractory lining 230 comprises a plurality ofstackable bricks of refractory material. In an alternative embodiment,refractory lining comprises a castable refractory material formed to fitthrough opening 204.

During operation, a portion of the syngas flowing through throat 228 maypass through a gap 232 between individual bricks 234 of refractorylining 230 or may pass through a crack 236 that may develop in a brick234 or in the castable refractory 230. The syngas leaking from throat228 into dome 210 may cause corrosion or high temperature degradation ofshell 202 or components (not shown for clarity) located within dome 210.In the exemplary embodiment, dome 210 may be purged and/or pressurizedby a flow of gas 238, such as nitrogen. Gas flow 238 may be supplied ata temperature that is much lower than the components within dome 210 orshell 202. Such a temperature differential may cause temperature stresson components or shell 202 that are exposed to flow 238. To preheat flow238 without using valuable heat from other portions of system 10, askirt 240 may be used to circumscribe throat 228. Flow 238 may besupplied to an annulus 242 formed between refractory lining 230 andskirt 240. Skirt 240 extends from shell 202 proximate opening 204vertically downward towards dome floor 211. A gap 244 permits flow 238to escape annulus 242 and enter dome 210. As flow 238 passes refractorylining 230, flow 238 absorbs heat transmitted through refractory lining230 from the high temperature syngas flowing through throat 228. Theheat absorbed by flow 238 increases the temperature of flow 238 so thatupon entry into dome 210 flow 238 is at a temperature that facilitatesreducing temperature differential stresses in the dome components andshell 202. Flow 238 exits dome 210 through gap 224. In the exemplaryembodiment, flow 238 is controlled by a valve 239 that may be setmanually based on a predetermined flow rate or may be modulated by acontrol system (not shown).

FIG. 3 is an elevation view of a portion of syngas cooler 18 inaccordance with another embodiment of the present invention. In theexemplary embodiment, a throat seal 300 comprises a cylinder 302circumscribing refractory lining 230. Throat seal 300 also includes acurved crown 304 that is concave toward dome 210 to accept thermalexpansion displacement. Crown 304 may be welded to cylinder 302 toprovide a seal therebetween. A top edge 305 of crown 304 may be weldedor otherwise coupled to shell 202 or may be frictionally engaged to aportion of refractory lining 230 to provide a seal or may be configuredwith a gap 306 to permit a predetermined flow of cooling medium toescape from an annulus 308 formed between refractory lining 230 andcylinder 302. A bottom edge 310 of cylinder 302 may be coupled to upperan waterwall 307 to provide support and sealing between dome 210 andannulus 308. Specifically, cylinder 302 may be welded to upper waterwall307 continuously about the circumference of bottom edge 310 or may bewelded intermittently such that a gap 312 is formed between bottom edge310 and upper waterwall 307. Gap 312 and/or gap 306 may be sized topermit a predetermined flow of cooling medium to cool refractory lining230 while preheating the cooling medium to facilitate reducingtemperature related fatigue and/or corrosion within dome 210. A supplyof cooling medium for example, but not limited to nitrogen, may beprovided from a source 314 external to cooler 18 through a conduit 316that penetrates shell 202 and seal 300 and channels the flow of coolingmedium into annulus 308.

FIG. 4 is an elevation view of a portion of syngas cooler 18 inaccordance with another embodiment of the present invention. In theexemplary embodiment, a throat seal 400 comprises a flexible bellows 402that includes a radially inner portion 404, an insulation portion 406,and a radially outer portion 408 that circumscribe refractory lining230. Inner portion 404 and outer portion 408 each include an upper edge410 and 412, a lower edge 414 and 416, and a corrugated body 418 and 420extending therebetween. In the exemplary embodiment, upper edges 410 and412 are coupled by welding to shell 202 and lower edges 414 and 416 arecoupled by welding to upper waterwall 307. In an alternative embodiment,edges 410 and 412 are welded to rings (not shown) to form a sealsub-assembly to facilitate installation and removal wherein thesub-assembly is bolted to shell 202 and upper water wall 307 using forexample, flange seals. Insulation portion 406 may substantially fill avoid 422 or may be thin enough to define a gap 424 between inner portion404 and insulation portion 406 and/or a gap 426 between insulationportion 406 and outer portion 408. In an alternative embodiment, throatseal 400 may comprise additional layers of alternating corrugatedbellows portions and insulation portions. Additionally, a plurality ofbellows portions and/or insulation portions may be spaced adjacently.Throat seal 400 further includes an upper drum 428 that circumscribesflexible bellows 402 and extends downward from shell 202. Throat seal400 also includes a lower drum 430 that extends upwardly from upperwaterwall 307 and circumscribes upper drum 428 to facilitate channelinga flow of cooling medium 432 through a tortuous path that provides apredetermined residence time proximate flexible bellows 402. Duringoperation, flow of cooling medium 432 is channel through a first passage434 defined between flexible bellows 402 and upper drum 428 and througha second passage 436 defined between upper drum 428 and lower drum 430.Flow of cooling medium 432 exits second passage 436 through gap 438defined between shell 202 and an upper edge 440 of lower drum 430.

The layered configuration described herein provides for a steppedtemperature gradient, wherein the temperature proximate flexible bellows402 both stays above the dewpoint of the syngas and heats the nitrogenfor the annular purge of dome 210. A first layer allows for heat to flowof cooling medium 432 while keeping radially inner portion 404 hot. Thesecond layer provides for heating flow of cooling medium 432 wherein therelatively cold metal proximate the second layer is not exposed tosyngas. The final layer is used to inject heated flow of cooling medium432 into dome 210.

FIG. 5 is a schematic diagram of an exemplary dome purge preheatingsystem 500 that may be used with gasifier 16 (shown in FIG. 1). During awarm-up of system 10, syngas cooler 18 may be preheated by circulatingsteam from an auxiliary source. A steam/water mixture flowing throughthe platens, warms the platen tubes and other components within syngascooler 18 by radiation, conduction, and convection. However, the vesselshell temperature lags in comparison to the steam tubes. Thistemperature differential creates a thermal stress at the interface ofthe syngas cooler tubes and the vessel shell.

Additionally, nitrogen injection at elevated pressure of approximately655 psig is used for syngas cooler 18 during operation. High pressurenitrogen is supplied by the air separation unit (ASU) in thegasification plant at a relatively low temperature of approximately 100°F. However, the metal surfaces inside the syngas cooler are at arelatively higher temperature for example, approximately 700-1200° F.during operation. If relatively cold nitrogen is injected into syngascooler 18 at a temperature much lower than the metal surfaces on theinterior of the vessel shell, life-limiting thermal stress may occur.

Dome purge preheating system 500 provides an additional heat source towarm the internals of syngas cooler 18 and reduces the temperaturedifferential between the syngas cooler tubes and vessel shell during thewarm-up process and to preheat purge nitrogen injected into dome 210during operation.

In the exemplary embodiment, dome purge preheating system 500 includes aflow of cooling medium 502, typically nitrogen supplied from ASU 14,however in an alternative embodiment, flow of cooling medium 502 may besupplied from any convenient source having a capacity to fulfill thefunctions described herein. During warm-up, flow of cooling medium 502is channeled through heat exchanger 504 where it receives heat fromblowdown water 506 or other continuous heated water source from a mainsteam drum 508 associated with steam generator 36. Flow of coolingmedium 502 is further channeled to a plenum 510 in heat transfercommunication with refractory lining 230. Flow of cooling medium 502 isdischarged into dome 210, having been warmed by blowdown water 506 orother continuous heated water source, to add heat to dome 210 tofacilitate the warm-up process. During operation, a flow of syngas 512from gasifier 16 passes refractory lining 230 giving up some of itsheat, which is then conducted to plenum 510 and some of the heat istransferred to flow of cooling medium 502. Warmed cooling medium 502 isdischarged into dome 210 to facilitate purging and warming of dome 210.A portion of the flow of cooling medium 502 may be bypassed using abypass valve 514 positioned in a bypass line 516. A flow of bypasscooling medium 518 is modulated to facilitate controlling a temperatureof the flow of cooling medium 502 so that a precise cooling medium 502temperature is maintained. At least some heat provided to the blowdownwater 506 is received from syngas cooler 18 through a riser 520 thatpenetrates shell 202 and a conduit 522 that channels a steam/watermixture to drum 508. The water and steam are separated in drum 508wherein the steam exits drum 508 through a main steam header 524 and thewater exits drum 508 and returns to syngas cooler 508 through downcomerpenetration 526 that penetrates shell 202.

FIG. 6 is a schematic diagram of another exemplary dome purge preheatingsystem 600 that may be used with gasifier 18 (shown in FIG. 1). In theexemplary embodiment, heat for preheating flow of cooling medium 502 isreceived from a drum blowdown sump 602.

FIG. 7 is a schematic diagram of another exemplary dome purge preheatingsystem 700 that may be used with gasifier 18 (shown in FIG. 1). In theexemplary embodiment, heat for preheating flow of cooling medium 502 isreceived from a heat exchanger coil 702 positioned within drum 508.

Exemplary embodiments of systems and methods for preheating and purginga pressure vessel space are described above in detail. The systems andmethods illustrated are not limited to the specific embodimentsdescribed herein, but rather, components of the system may be utilizedindependently and separately from other components described herein.Further, steps described in the method may be utilized independently andseparately from other steps described herein.

While embodiments of the disclosure have been described in terms ofvarious specific embodiments, it will be recognized that the embodimentsof the disclosure can be practiced with modification within the spiritand scope of the claims.

1-20. (canceled)
 21. A syngas cooler system comprising: a pressurevessel comprising a throat and a dome adjacent to said throat, saidthroat comprises an area of excess heat, said dome comprising an area ofdeficient heat; a conduit extending from an interior of said pressurevessel; a plenum extending between said throat and a bellows assemblycoupled at least partially within said dome; and a conduit coupled tosaid plenum for channeling a flow of purge fluid from external to saidpressure vessel into said plenum to such that purge fluid transfers heatfrom said area of excess heat into said area of deficient heat tofacilitate reducing temperature differential stresses within said domeand said pressure vessel.
 22. A system in accordance with claim 21wherein said bellows assembly comprises a plurality of substantiallycylindrical bellows circumscribing said conduit wherein an insulationlayer extends between at least some of plurality of substantiallycylindrical bellows.
 23. A system in accordance with claim 22 whereinsaid plenum further comprises a tortuous path defined therein, saidplenum positioned radially outward from said plurality of bellows, saidplenum supplied with a flow of purge gas that channels heat from saidplurality of bellows.
 24. A system in accordance with claim 22 whereinsaid pressure vessel further comprises a substantially planar floorseparating said vessel into a first compartment and a secondcompartment, said first compartment in flow communication with saidsecond compartment via an aperture extending through said floor.
 25. Asystem in accordance with claim 24 wherein said pressure vesselcomprises an outer shell including a penetration therethrough.
 26. Asystem in accordance with claim 22 wherein said each said insulationlayer facilitates creating a stepped temperature gradient within saidpressure vessel.
 27. A system in accordance with claim 26 wherein eachsaid insulation layer facilitates maintaining a temperature proximatesaid plurality of bellows above a dewpoint of syngas flowing throughsaid pressure vessel.
 28. A system in accordance with claim 22 whereinsaid throat comprises a refractory based lining.
 29. A system inaccordance with claim 22 further comprising a supplemental heatexchanger having a first flow path coupled in flow communication withsaid plenum, said heat exchanger configured to add supplemental heat tothe flow of purge fluid.
 30. A system in accordance with claim 22wherein said supplemental heat exchanger further includes a second flowpath in thermal communication with the first flow path, the second flowpath coupled in flow communication with a source of supplemental heat.31. A system in accordance with claim 22 wherein heat from the area ofexcess heat is transferred to the flow of purge fluid in said plenum andthe heat is carried by the flow of purge fluid into the area ofdeficient heat such that the flow of purge fluid simultaneously purgesthe area of deficient heat.